KOB PYROT SERIES, PYROT 100, PYRTEC 540, PYRTEC 300 Operation And Maintenance Instructions
Operation and Maintenance Instructions
PYROT 100 to 540
ID: 106811-H English
© by KÖB Holzfeuerungen GmbH
Flotzbachstraße 33
A-6922 Wolfurt
All rights reserved, including photomechanical
reproduction and storage in electronic media.
Viessmann Group
1 General Information_________________________________________________ 4
1.1 Foreword _______________________________________________________________________ 4
1.2 Technical standing _______________________________________________________________ 4
1.3 Intended use ____________________________________________________________________ 4
1.4 Technical data___________________________________________________________________ 4
1.5 Information documented __________________________________________________________ 4
1.6 CE-certification __________________________________________________________________ 4
2 Important Information _______________________________________________ 5
2.1 Safety instructions _______________________________________________________________ 5
2.2 Excess temperature/power failure __________________________________________________ 5
2.3 Low water/excess water pressure___________________________________________________ 5
2.4 A fire hazard ____________________________________________________________________ 6
2.5 Wood fuels, minimum requirements_________________________________________________ 6
2.6 Filling the fuel storage unit ________________________________________________________ 6
2.6.1 By dumping ______________________________________________________________________ 6
2.6.2 By blowing in_____________________________________________________________________ 6
2.7 Correcting malfunctions in the feed systems _________________________________________ 6
3 How the Boiler Plant is Strucured _____________________________________ 7
4 Commissioning/Operation ___________________________________________ 8
4.1 The initial start-up________________________________________________________________ 8
4.2 Operation_______________________________________________________________________ 8
4.2.1 Heating up_______________________________________________________________________ 8
4.2.2 Operation _______________________________________________________________________ 8
4.2.3 Switching off _____________________________________________________________________ 8
5 Oil burners on a Pyrot_______________________________________________ 9
6 The ECOTRONIC control system _____________________________________ 10
6.1 General information _____________________________________________________________ 10
6.1.1 Replacing the battery _____________________________________________________________ 10
6.2 The functions of the keys_________________________________________________________ 10
6.3 Boiler and loader system (F3/F4)___________________________________________________ 11
6.3.1 The F3 KEY: "PYROT Parameters" __________________________________________________ 11
6.3.2 The F4 KEY: "PYROT Loader System" _______________________________________________ 12
6.4 Extended control systems F5 – F8 (optional)_________________________________________ 13
6.4.1 Room heating system _____________________________________________________________ 13
6.4.2 Utility water heater _______________________________________________________________ 15
6.4.3 Air heater ______________________________________________________________________ 16
6.4.4 Annex buildings__________________________________________________________________ 17
6.4.5 Pipelining ______________________________________________________________________ 18
6.4.6 Additional heat generator __________________________________________________________ 19
6.4.7 Solar __________________________________________________________________________ 20
7 Cleaning/Maintenance______________________________________________ 21
7.1 Boiler _________________________________________________________________________ 21
7.1 Installing the displacement rods into the heat exchanger ______________________________ 23
7.2 Feed systems __________________________________________________________________ 24
8 Shutdown ________________________________________________________ 24
9 Carrying out disposals _____________________________________________ 24
10 Supplements
- Spec Sheet 1010-1, 2
- Malfunction report/Malfunction correction
4
1 General Information
1.1 Foreword
Dear System Owner, you have made a good selection in the PYROT. It will provide you with all
the advantages of a modern, economically efficient heating system. Fully developed technology
in combination with a sturdy design guarantee a
high degree of operational reliability and a long
service life.
These Operating and Maintenance Instructions
contain important information for the intended
use, correct operation and proper maintenance of
the PYROT.
Non-compliance with the Operating and Maintenance Instructions will result in loss of the
guarantee.
If you still need any further information after studying the Operating and Maintenance Instructions:
The Assembly and Installation Instructions contain
important information about:
- Standards and regulations
- Structural surroundings of the boiler plant
- Transport and assembly
- Water installation and electrical installation
- Fire protection
- Commissioning
as well as an appendix with diagrams of connections and dimensions and the complete technical
specifications.
Our sales and services offices will be glad to provide you with any further information. Their addresses can be found on the reverse side of these
Operating and Maintenance Instructions.
1.2 Technical standing
The Operating and Maintenance Instructions are
in keeping with the PYROT at the time it is delivered. In the interest of our customers, we reserve
the right to make, without any notification requirement, subsequent changes resulting from
further technology developments.
1.3 Intended use
The intended use of the PYROT is for incinerating
wood fuels.
The intended use of the PYROT is stipulated:
- in the regulations of the Assembly and Installation Instructions
- by the limits of the technical specifications
- in Spec Sheet 1010 "Minimum Requirements
for Wood Fuels/Instructions"
- by the safety regulations in these Operating
and Maintenance Instructions.
Any other use of the PYROT or use of it going beyond this will be considered as unintended use
unless written approval by the manufacturer has
been obtained.
- Operation of the PYROT by unqualified personnel, without any training or knowledge of
the Operating and Maintenance Instructions.
- Disabling the safety or monitoring devices on
the PYROT.
- Removal of any protective covers or cladding
on the PYROT by unauthorised individuals.
- Making any conversions or alterations to the
PYROT without approval by the manufacturer.
- Using spare parts or accessories from other
manufacturers without approval by the manufacturer.
The operating organisation will be liable for
any damage or accidents in case of any unintended use.
1.4 Technical data
The following important limit values apply to the
PYROT heating boiler:
- Max. operating pressure allowed ...........3.0 bar
- Max. boiler temperature allowed .............100°C
- Min. return flow temperature allowed ........65°C
The complete technical specifications are listed in
the appendix of the Assembly and Installation Instructions.
1.5 Information documented
The Operating Instructions contain the information
required according to the EC Directive on Machinery 98/37/EEC, Appendix 1, Number 1.7.4.
Issue: 2007-08_English
Prepared by: KaW/SclM
1.6 CE-certification
The PYROT is delivered with a CE-symbol on its
type plate and an EC attestation of conformity in
accordance with Appendix II A of the EC Directive
on Machinery 98/37/EEC.
If the PYROT is altered by equipment from other
manufacturers being added, or the safety equipment or control system are combined with a different system and/or integrated into an overriding
system (building control system, etc.), then in the
European Union a new attestation of conformity
has to be issued before it is put on the market.
5
2 Important Information
2.1 Safety instructions
When carrying out work on the heating sys-
tem, such as cleaning and maintenance, wear
appropriate protective equipping when required.
There is a danger of getting injured through:
burning, knocking against corners and edges,
crushing in moving parts and noise.
Mains supply: 400V C
In a risky situation, the PYROT can be disconnected from the electrical mains at all the leads by
the master switch on the control cabinet
Doors
CAUTION
FIRE HAZARD:
The boiler plant must never be operated with
the doors open! Red-hot objects that might
escape could result in fires.
RISK OF INJURY:
If the doors are open during operation, sparks
or flames could leap out.
Equipment for dissipating excess heat
The operational reliability of the thermal run-off
safety valve should be examined annually by a
competent specialist. The safety heat exchanger
must not by any means be used as an operational
heat exchanger.
Seals
For the functioning and controllability of the
burner, it is important that no unwanted air can
leak in, entering unchecked through leaky spots.
The doors and lids have to shut tight − any damaged seals must be replaced immediately.
Tighten the retaining screws and handles snugly.
Operation, cleaning & maintenance
Bear in mind that only if operated and maintained
properly can even the best of products fulfil their
functions well, doing so for a long time and free of
malfunctions.
Compliance with the "Cleaning" section is mandatory!
2.2 Excess temperature/power failure
CAUTION
DANGER OF THIS SUDDENLY GOING UP IN
FLAMES:
Do not open the doors or lids on the boiler
plant!
- Switch on additional heat consumers.
- The exhaust fan goes out of operation.
- The temperature-limiting safety switch triggers.
- The valve for the thermal run-off safety valve
opens at approx. 95°C. The excess heat is
conducted off into the channel.
If the temperature-limiting safety switch
(TLSS) has triggered, then it has to be manually unlocked. The TLSS is situated at the top
of the boiler.
To reset, unscrew the black cap and press the
button.
NOTE:
Only as of a temperature of approx. 70°C
resetting is possible.
Possible causes for excess temperature:
- Incorrect setting on the control module.
- Defective component of the system (pump or
valve).
- Sudden drop in output to zero. The feed auger
still has to be emptied. The heat yet produced
by this can result in surplus temperature. Activate "DISSIPATE SURPLUS HEAT" function!
2.3 Low water/excess water pressure
Possible causes:
1. Low water: Leakage in the heating system.
2. Excess water pressure: The expansion system
not functioning.
In either case, one should have the facility examined by a competent heating installer.
Unlock this malfunction with either the reset
button for the water level control system or for
the overpressure monitor, and by pressing the
OK key on the control panel.
6
2.4 A fire hazard
With insertion-type firing systems, the conveying
route creates a connection between the silo and
the burning material in the boiler plant.
With the PYROT insertion-type heating boiler, the
feed auger is also the metering auger, and is thus
always filled up with material during operation
There are various safety devices provided to prevent burn-back.
Temperature sensors:
By means of temperature sensors on the feed auger, in case of excess temperature the loading to
the feed auger is interrupted, and the feed auger's
material is inserted into the combustion chamber.
Slide valve (optional):
This closes in case of a standstill, danger of burnback or power failure (spring return motor).
Rotary valve (optional):
Instead of a slide valve, in silos with pressurisation.
Drop-off route:
A vertical drop-off section interrupts the connected line of burning material.
Fire-extinguishing system (option):
This system, which functions independently of the
electrical power, brings about a flooding of the
material to be burned that is located in the feed
auger. The activation temperature is approx.
95°C.
2.5 Wood fuels, minimum requirements
The PYROT is only suitable for incinerating the
fuels listed in Spec Sheet 1010 "Minimum Requirements for Wood Fuels" (see supplement).
If different fuels are used, KÖB will not assume any liability for the functioning or service life of the boiler plant. Refer to the "Warranty" section in the General Terms and Conditions of Delivery.
2.6 Filling the fuel storage unit
2.6.1 By dumping
Rotary sweep extraction and spring-operated
extraction
Heating system in operation:
- If the articulated arms or spring-mounted
plates are still covered by fuel
, refilling can be
carried out immediately.
- If the articulated arms or spring-mounted
plates are no longer covered by fuel
, fill the silo
evenly to approx. 30 cm above the articulated
arm or over the spring-mounted plates. As
soon as the articulated arms or springmounted plates have retracted through a request for material, the refilling can be continued.
Heating out of operation
:
- If the articulated arms or spring-mounted
plates are still covered by fuel
, refilling can be
carried out immediately.
- If the articulated arms or spring-mounted
plates are no longer covered by fuel
, fill the silo
evenly to approx. 30 cm above the articulated
arm or over the spring-mounted plates. Then
activate the "SILO FILLING" function. To do
so, press the LOADER SYSTEM key (F4) and
then the left arrow key (<). Then select "YES"
and confirm with "OK". Wait until the articulated arms or the spring-mounted blades go
under the cup washer, and then finish evenly
filling the silo. The "SILO FILLING" function
brings about the filling of the fire box.
NOTE: The "SILO FILLING" function cannot be
activated until the heating system has been
out of operation for one hour.
Moving floor conveyor
- Fuel can be refilled automatically.
Funnel extraction system
- It is mandatory that the heating system be in
operation!
2.6.2 By blowing in
The heating system has to be out of operation
(danger of excess pressure or negative pressure caused by the action of blowing-in). Filling procedure as described in section 2.6.1.
2.7 Correcting malfunctions in the feed sys-
tems
The cause of motor malfunctions in feed systems
is usually clogging by large pieces of wood or foreign matter.
CAUTION
DANGER OF INJURY:
Always turn off the master switch before carrying out any repair of a malfunction on feed
systems and every time before a maintenance
lid is opened or a protective device is removed!
The automatic operation of the system makes it
impossible to foresee the time point when the
conveying equipment will switch on.
7
3 How the Boiler Plant is Strucured
(Illustration: PYROT 300)
(1) Feed auger with isolating layer
(2) Drive for moving grate
(3) Automatic ignition device
(4) Controlled combustion air supply system
(5) Moving grate
(6) Drive for automatic de-ashing system (op-
tional)
(7) Rotation fan (KÖB-patented)
(8) Rotation combustion chamber (KÖB-
patented)
(9) Boiler heat exchanger
(10) Boiler door
(11) Heat exchanger for thermal run-off safety
valve
(12) Speed-controlled exhaust fan
(13) Recirculated flue gas pipe (optional)
(14) Automatic cleaning system (optional)
12
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2
3
4
5
6
7
8
9
10
13
4
14
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4 Commissioning/Operation
4.1 The initial start-up
The initial start-up is carried out either by KÖB
Holzfeuerungen GmbH or a competent individual
named by it.
Be absolutely sure to follow the instructions in
the Assembly and Installation Instructions. No
guarantee may be claimed for damages in
cases of initial start-ups carried out improperly at one's own initiative.
First check:
- Is there enough water in the heating system?
- Has the heating system been bled of air?
- Are the slide valves open for the heating-
system's forward and reverse flow?
- Can enough fresh air get into the heating
room?
- Empty ash bin.
- Are the doors and lids on the burner all closed
leak-tight?
4.2 Operation
4.2.1 Heating up
- Press the F1 key "PYROT Wood". The loader
modules will be switched on in the appropriate
order. When there is enough fuel in the combustion chamber, the entire loader system
switches off.
- The automatic ignition then takes place. The
ignition process stops as soon as the fire is
started.
4.2.2 Operation
- The material is supplied depending on the light
barriers in the metering container and in the
combustion chamber, allowing for the residual
oxygen.
- The primary and secondary air vents change
their positions depending on the exhaust gas
temperature and residual oxygen.
- Using the setting "Storage Management, Temperature, Storage, Average", it is possible to
keep the facility in continuous highperformance operation for as long as possible
– with fewer ignitions, better efficiency and lower emissions.
(Only possible with accumulator option)
- When the boiler temperature set is reached,
the facility switches to "Run Auger Empty".
When the feed auger has been run empty, and
the exhaust gas temperature is less than 90°C,
the exhaust gas fan switches off and the air
vents close.
- When the "System Temperature Setting" is
fallen short of, the facility is automatically started back up.
4.2.3 Switching off
- Press the F1 key "PYROT Wood". As feedback to this, "Run Auger Empty" will appear on
the control panel.
CAUTION: Do NOT use the master button to
switch off (DANGER OF BACK BURN) !!!
9
5 Oil burners on a Pyrot
Be sure to note:
- The oil burner's firing power may amount to a
maximum of 70% of the rated heat output in
wood-burning operation.
- The selection of the oil burner as well as the
actual nozzle length have to be determined by
the supplier of the oil burner.
- Only either wood-burning operation or oilburning operation is possible.
- For wood-burning operation, put in the sealing
plug.
- Close the flue gas recirculation system.
- Set the speed of the exhaust fan such that the
flame only reaches halfway up the fireclaylined flame tube.
10
6 The ECOTRONIC control system
6.1 General information
The ECOTRONIC facility control system is a decentralised microprocessor system (CAN-BUS)
developed by KÖB with various modules that are
connected by a data transmission line.
Its function
The ECOTRONIC records all the data relevant to
operation and controls the supply of and demand
for heat.
Thus the boiler plant is continuously monitored
during all the operating phases and kept within an
optimum range in terms of emissions.
Factory settings (pre-settings)
All the parameters in the ECOTRONIC, such as
set point values and switching times, are pre-set
and can be called back up at any time. The figures for the factory settings are given in brackets
for the various parameters.
6.1.1 Replacing the battery
There is a battery built in beneath the removable
lid on the control module (type: Panasonic Lithium BR2330). It is for buffering the time, date and
settings.
- The battery needs replacing every five
years!
- Do not disconnect the mains voltage while
changing the battery (do not turn off master
switch)!
6.2 The functions of the keys
F1 (PYROT Wood)
Switch WOOD operation on and off
F2 (PYROT Oil)
Switch OIL OPERATION on and off
F3 (PYROT Parameters)
Setting parameters, set point values, the date and
time
F4 (PYROT Loader System)
Setting of cycle switchover switching, advanceflow and post-flow times
F5 (Group 1)
Setting parameters and set point values
(heat distribution, Group 1)
F6 (Group 2)
Setting parameters and set point values
(heat distribution, Group 2)
F7 (Group 3)
Setting parameters and set point values
(heat distribution, Group 3)
F8 (Group 4)
Setting parameters and set point values
(heat distribution, Group 4)
< Go one page to the left in menu masks
> Go one page to the right in menu masks
∧ Go one line up
(Only possible when the scroll up symbol Ï
is displayed.)
∨ Go one line down
(Only possible when the scroll down symbol
Ð is displayed.)
+ Change numeric values and set point val-
ues
- Change numeric values and set point val-
ues
OK Adopt (acknowledge) settings and/or
changes
The following applies to the F3, F4, F5, F6, F7
& F8 buttons:
- Pressing once will take you to the respective
menu. As feedback, the relevant LED will blink.
- If a set point value is changed and not confirmed with "OK", then it will not be adopted.
- Pressing the function button again will bring
back the standard display.
- When no button is pressed for a period of sixty
seconds, the standard display automatically
reappears.
BE SURE TO NOTE:
Depending on the design and setting, some
menus and texts do not appear.
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